Public service announcement: Don't use anything other than stainless hardware in the factory roof rivnuts/nutserts. When I installed my aluminum rack (that is still for sale, by the way
), I thought the shiny silver stainless stuff looked bad against the cool black powdercoated rack. So I purchased black zinc oxide hardware instead. Well, fast forward a couple of years when I go to pull that rack off and replace it with my new front runner rack, and nearly every single bolt had rusted up inside the threaded inserts (rivnuts) on the roof. Nearly all of the ruvnuts ended up breaking free, spinning loose in the roof instead of allowing the bolts to back out of them.
What a PITA. I removed the headliner and was able to clamp vice grips onto the back of most of them in order to finish backing the bolts out. Some of them are blocked by structural supports, and required force to remove the entire rivnut from the roof (which leaves an awful mushroom shaped hole.
). Anyway, I spent all day yesterday drilling them all out and installing new ones that I ordered online. Sealed the holes up with silicone as I installed them to prevent any leaks. And yes, I know my roof is extremely dirty. I'll be washing it before the new rack gets installed.
The culprits:
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Headliner removed:
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New rivnut installed. So beautiful:
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Here's the combination of parts I used to install them, in place of a proper tool. Worked well, but I went through about 3 or 4 of those star washers:
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The installation process. My hand and arm are super sore from the amount force required on that ratchet. I didn't want to use something mechanical though, for fear of over-tightening them:
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A dab of clear silicone around each hole before installing the new nuts. This was especially important, as the metal was pretty messed up around a few of them from removing them:
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"Saudi Spec," as knight rider would say. I wonder how much better my gas mileage is now.
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